![Kawasaki KR250 [118/183] Disassembly](/img/pdf.png)
Kawasaki KR250 [118/183] Disassembly
![Kawasaki KR250 [118/183] Disassembly](/views2/1121209/page118/bg76.png)
Содержание
- Quick reference guide 2
- General information 3
- Table of contents 3
- Genera 5
- 8 general information 10
- Air cleaner e i em ent rep lace 5 cleanings 10
- Air cleaner element clean 10
- Battery electrolyte level check f month 10
- Brake fluid change 2 years 10
- Brake fluid level check t month 10
- Brake light switch check f 10
- Brake pad wear check f 10
- Caliper piston seal and dust seal replace 2 years 10
- Check f 10
- Clutch adjust 10
- Coolant change 2 years 10
- Cylinder head bolts check f 10
- Drive chain lubricate every 300 km 10
- Drive chain slack check f every 800 km_______________________ 10
- Drive chain wear check f 10
- For higher odometer readings repeat at the frequency interval established here t replace add adjust or torque if necessary 10
- Frequency 10
- Front fork oil change 10
- Fuel hose replace 4 years 10
- Fuel system clean 10
- General lubrication perform 10
- Good running condition 10
- Idle speed check f 10
- Master cylinder cup and dust seal replace brake hose replace 10
- Nuts bolts fasteners check t 10
- Oh pump and carburetor synchronization 10
- Operation 10
- Periodic maintenance chart 10
- Radiator hoses connections check f year 10
- Spark plug clean and gap t 10
- Steering play check 10
- Steering stem bearing lubricate 2 years 10
- Swing arm pivot lubricate 10
- The initial maintenance is vitally important and must not be neglected 10
- The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in 10
- Throttle grip play check t 10
- Tire wear check 10
- Transmission oil change year 10
- Whichever con hrsth _ odometer reading 10
- Years 4 years 10
- 1 11 0 13
- Coolant temperature sensor 15 1 11 ss 13
- Electrical system 13
- Fastener torque 13
- General information 1 11 13
- Magneto rotor bolt 69 7 13
- Neutral switch 13
- Nm kg m ft lb 13
- Remarks 13
- Side stand switch mounting screws 13
- Spark plugs 27 2 13
- 12 general information 14
- Suggested wiring cable ar hase routing 14
- General information 1 13 15
- General information 16
- V iflfeiv v j j 16
- ______ 16
- General information 1 15 17
- 16 general information 18
- General information 1 17 19
- 18 general information 20
- General information 1 19 21
- Fuel system 22
- Table of contents 22
- Fuel system 25
- Specifications special tools 25
- Fuel system 2 5 26
- Grip play inspection 26
- Throttle grip and cables 26
- Throttle grip play adjustment 26
- Warning 1 26
- 3 fuel system 27
- Choke cable adjustment 27
- Choke cables 27
- Throttle cable inspection 27
- Throttle cable lubrication 27
- Throttle cable removal note 27
- Warmins 27
- Carburetors 28
- Choke cable inspection 28
- Choke cable lubrication 28
- Choke cable removal 28
- Fuel system 2 7 28
- I die speed adjustment 28
- Warning i 28
- 8 fuel system 29
- Fuel level inspection 29
- Float removal 30
- Fuel level adjustment 30
- Fuel system 2 9 30
- Fuel system cleanliness inspection 30
- Warn img 30
- Carburetor cleaning 31
- Carburetor installation notes 31
- Carburetor removal 31
- Id fuel system 31
- Warnin 31
- Warning i 31
- Carburetor inspection 32
- Fuel system 2 11 32
- Warming 32
- 12 fuel system 33
- Air cleaner 33
- Air cleaner element removal installation 33
- Caution 33
- Element inspection and cleaning 33
- Warning 33
- A ir cleaner housing removal 34
- Air cleaner housing installation note 34
- Fuel system 2 13 34
- Fuel tank 34
- Fuel tank removal 34
- Warning 34
- Warning j 34
- 14 fuel system 35
- Fuel tank and tap cleaning 35
- Fuel tap assembly note 35
- Fuel tap inspection 35
- Fuel tap installation note 35
- Wardin 35
- Fuel system 2 15 36
- Fuel tank and cap inspection 36
- Reed valve 36
- Reed valve inspection 36
- Reed valve removal 36
- 16 fuel system 37
- Idle speed adjustment from page 2 8 37
- Warming 37
- Cooling system 38
- Table of contents 38
- 2 cooling system 39
- Exploded view 39
- 1 cooling system 41
- Cautio 41
- Coolant 41
- Coolant deterioration 41
- Coolant draining 41
- Coolant level inspection 41
- Warniwc 41
- Caution 42
- Coolant filling 42
- Cooling system 3 5 42
- Caution 43
- Cooling system 43
- Cooling system flushing 43
- Cooling system pressure testing 43
- Visual leak inspection 43
- Caution 44
- Cooling system 3 7 44
- Disassembly and assembly precautions 44
- Pump cover removal 44
- Pump impeller removal installation notes 44
- Water pump disassembly 44
- Water pump mechanical seal 44
- 8 cooling system 45
- Pump assembly notes 45
- Cooling system 3 9 46
- Mechanical seal inspection 46
- Radiator 46
- Radiator inspection 46
- Radiator removal 46
- 10 cooling system 47
- Radiator cap inspection 47
- Thermostat 47
- Thermostat inspection 47
- Thermostat installation note 47
- Cautíorh 48
- Cooling system 3 11 48
- Installation notes 48
- Removal caution 48
- Water temperature sensor 48
- Engine top end 49
- Table of contents 49
- Engine top end 4 3 51
- Caution 53
- Compression measurement 53
- Cylinder head 53
- Cylinder head removal 53
- Engine top end 4 53
- 6 engine top end 54
- Cylinder head installation notes 54
- Cylinder head warp inspection 54
- Exhaust valve kips 54
- Exhaust valve operating unit removal 54
- Cautio 55
- Engine top end 4 7 55
- Exhaust valve installation notes 55
- Exhaust valve operating unit installation 55
- 8 engine top end 56
- Cylinder assembly note 56
- Cylinder installation notes 56
- Cylinder piston 56
- Cylinder removal 56
- Cylinder wear inspection 56
- Caution 57
- Engine top end 4 9 57
- Piston installation notes 57
- Piston removal notes 57
- 10 engine top end 58
- Piston cylinder clearance 58
- Piston diameter measurement 58
- Piston ring piston ring groove inspection 58
- Connecting rod wear inspection 59
- Engine top end 4 11 59
- Muffler 59
- Muffler removal 59
- Piston piston pin 59
- Piston rins end gap 59
- Engine top eno 60
- Muffler installation notes 60
- Engine right side 61
- Table of contents 61
- Clutch 64
- Clutch adjustment 64
- Dutch adjustment check 64
- Engine right side 64
- Washing 64
- Caihion 65
- Clutch cable removal 65
- Clutch cover installation note 65
- Clutch cover removal 65
- Clutch removal 65
- Dutch release lever shaft installation note 65
- Engine right side 5 5 65
- 6 engine right side 66
- Caution 66
- Clutch installation notes 66
- Clutch spring free length measurement 67
- Engine right side 5 7 67
- Friction or steel plate warp inspection 67
- Friction plate wear damage inspection 67
- 8 engine right side 68
- Clutch housing finger inspection 68
- Dutch hub spline inspection 68
- Right engine cover 68
- Right engine cover removal 68
- Caution 69
- Engine right side 5 9 69
- Right engine cover installation 69
- Engine right side 70
- Kickstarter 70
- Kickstarter installation notes 70
- Kickstarter removal 70
- Engine lubrication system 71
- Table of contents 71
- 2 engine lubrication system 72
- Exploded view 72
- Engine lubrication system 74
- Oh changing 74
- Oh level inspection 74
- Warn ims 74
- Bleeding the oh pump 75
- Engine lubrication system 6 5 75
- Engine oil pump 75
- Oil pump and carburetor synchronization 75
- Synch roniza tion a djus men t 75
- Synchronization inspection 75
- 6 engine lubrication system 76
- Off pump check valve inspection 76
- Oh pump performance test 76
- Cautio 77
- Engine lubrication system 6 7 77
- Engine oil tank 77
- Engine oil tank removal 77
- Oh pump removal 77
- Oil pump assembly caution 77
- Oil pump installation notes 77
- 8 engine lubrication system 78
- Cautio 78
- Ou tank installation notes 78
- Engine removal lnstallation 79
- Table of contents 79
- Engine removal installation 7 3 81
- Engine removal instanation 81
- Nstahation 81
- Removal 81
- Warnin 81
- Crankshaft transmission 82
- Table of contents 82
- Crankshaft transmission 8 3 84
- Crankcase assembly notes 86
- Crankcase replacement 86
- Crankcase splitting 86
- Crankshaft transmission 8 5 86
- Connecting rod big end radial clearance 87
- Crankfhah connecting rod 87
- Crankshaft installation notes 87
- Crankshaft transmissiqn 87
- Connecting hod big end seizure 88
- Connecting hod big end side clearance 88
- Crankshaft alignment 88
- Crankshaft runout 88
- Crankshaft transmission 8 7 88
- Caution 89
- Cran kshaft transmission 89
- Externa shift mechanism installation notes 89
- External shift mechanism removal 89
- Shift pedal installation note 89
- Transmission 89
- C ran kshaft tr ansmission 8 9 90
- Shift drum installation notes 90
- Shift drum removal 90
- Transmission shaft shift fork 90
- Warming 90
- 10 crankshaft transmission 91
- Transmission assembly notes 91
- Transmission disassembly 91
- Balancer 92
- Balancer shaft installation 92
- Balancer shaft removal 92
- Crankshaft transmission 8 11 92
- 12 crankshaft transmission 93
- Balancer cover replacement 93
- Cautio 93
- Table of contents 94
- Wheels tîres 94
- Exploded view 95
- Wheels ures 95
- Bead breaker fp n 57001 1072i 97
- Special tools 97
- Tire irons p n 5700 f 1073j sre included in the 97
- Wheels tires 97
- Cautionj 98
- Front wheel installation notes 98
- Front wheel removal 98
- Wheels rims 98
- Wheels tires 9 98
- 6 wheels tires 99
- Rear wheel removal 99
- Warning 99
- Balance weight installation 100
- Cautionj 100
- Rear wheel installation notes 100
- Wheel rim inspection 100
- 8 wheels tires 101
- Balance weight removal 101
- Tire air pressure inspection 101
- Fiemovaf 102
- Hub bearings 102
- Tire fnstaftàtion 102
- Tire inspection 102
- Wheels tires 9 9 102
- 10 wheels tires 103
- Cautio 103
- Disassembly and assembly 103
- Inspection 103
- Installation 103
- Lubrication 103
- Speedometer gear housing 103
- Final drive 104
- Table of contents 104
- 2 final drive 105
- Exploded view 105
- Drive chain 107
- Drive chain slack adjustment 107
- Wheel alignment adjustment 107
- Л final drive 107
- Юл final drive 107
- Drive chain installation notes 108
- Drive chain removal 108
- Drive chain wear inspection 108
- Final drive 10 5 108
- Warning 108
- 6 final drive 109
- Caution 109
- Drive chain lubrication 109
- Engine sprocket installation notes 109
- Engine sprocket removal 109
- Sprocket coupling 109
- Warning 109
- Coupling bearing installation note 110
- Coupling bearing lubrication 110
- Final drive 10 7 110
- Rear sprocket installation votes 110
- Rear sprocket removal 110
- Sprocket warp 110
- Warming 110
- Brakes 111
- Table of contents 111
- Brakes 11 3 113
- Brake pedal 115
- Brake pedal position adjustment 115
- Brakes 11 5 115
- Caliper 115
- Front caliper removal 115
- 6 brakes 116
- Assembly notes 116
- Caliper insta flation notes 116
- Disassembly notes 116
- Rear caliper removal 116
- Warning i 116
- Brake pads 117
- Brakes 11 7 117
- Front master cylinder installation 117
- Installation notes 117
- Lining wear 117
- Master cylinders 117
- Removal 117
- Torque link assembly note 117
- Warning 117
- 8 brakes 118
- Disassembly 118
- Inspection and adjustment after installation 118
- Note the following 118
- Rear master cylinder installation 118
- Rear master cylinder removal 118
- Assembly 119
- Brake disc 119
- Brakes 11 9 119
- From disc installation notes 119
- Inspection visually i 119
- Apply non permanent locking agent to the threads of 120
- Brake di1c 120
- Brake disc 2 measuring area 120
- Brake disc mounting nuts front axle clamp bolts front 120
- Brake fluid 120
- Check the brake fluid level in the reservoir 120
- Fluid level inspection 120
- General information chapter 120
- Ii runout exceeds the service limit replace the disc 120
- Lower level line 2 lipper level 120
- Measuring area 120
- Nut brake caliper mounting bolts side stand bracket mounting bolts 120
- Replace the disc if it has worn past the service limit 120
- Side stand bracket mounting bolts 120
- Tighten the following parts to the specified torque see 120
- Tv10 brakes 120
- Warning 120
- Alter a clear plastic hose to the bleed valve on the 121
- Brake fluid change 121
- Brakes 11 11 121
- Caliper and run the other end of rhe hose into a container 121
- Change the brake fluid as fellows 121
- Check the fluid level in the reservoir often replenishing 121
- Fluid level 121
- Follows changing the rear brake fluid is the sarne as for the front brake 121
- Hold the reservoir horizontal when checking brake 121
- I open the bleed valve 2 apply the brake and hold it 3 close the bleed valvp 4 release the brake lever 121
- If the fluid in the reservoir runs completely out any 121
- It as necessary 121
- Lower level line 2 upper level line 121
- On the bleed valve 121
- Procedure to change the front brake fluid is as 121
- Remove the reservoir cap and remove the rubber cap 121
- Tf the fluid level is lower than the lower level line fill 121
- The reservoir to the upper level line of the reservoir 121
- Time during fluid changing the bleeding operation must be done over again from the beginning since air win have entered the line 121
- Warning 121
- 12 brakes 122
- Bleeding the brake line 122
- Warning 122
- Brakes 11 13 123
- Warnin 123
- Suspension 124
- Table of contents 124
- 2 suspension 125
- Exploded view 125
- Front fork 127
- Suspension 127
- Warning 127
- Suspension 12 5 128
- 6 suspension 129
- Warning 129
- Assembly notes 130
- Guide bush inspection 130
- Inner tube inspection 130
- Suspension 12 7 130
- 8 suspension 131
- I ii hl 131
- Oh seal and dust seal inspection 131
- Rear shock absorber 131
- Rear suspension uni trak 131
- Rebound damping force adjustment 131
- Spring force adjustment 131
- Spring tension 131
- Suspension 12 9 132
- Swing arm 132
- Warning 132
- 10 suspension 133
- Caution 133
- Tie rod rocker arm 133
- Warning j 133
- Bearing lubrication 134
- Needle bearing inspection 134
- Rocker arm installation 134
- Rocker arm removal 134
- Suspension 12 11 134
- Tie rod installation 134
- Tie rod rocker arm needle 134
- Tie rod rocker arm sleeve inspection 134
- Steering 135
- Table of contents 135
- 2 steering 136
- Exploded view 136
- Special tools 137
- Steering 13 3 137
- Steering 138
- Steering stem 138
- Warning 138
- Installation 139
- Steering 13 5 139
- 6 steering 140
- Bearing lubrication 140
- Bearing wear damage 140
- Steering stem bearing 140
- Steering stem warp 140
- Stem cap deterioration damage 140
- Table of contents 141
- Fairings fender 144
- Lower fairing installation note 144
- Lower fairing removal 144
- Rear fender front section removal 144
- Rear fender rear section removal 144
- Upper fairing removal 144
- Frame 14 5 145
- Seat cover 145
- Seat cover installation 145
- Electrical system 146
- Table of contents 146
- Electrical system 15 3 148
- Precautions 148
- Electrical system 149
- Parts location 149
- Australian and south african models 150
- Bk r rk v 150
- Electrical system 155 150
- Kr250 b1 b2 wiring diagram 150
- Küilüüh 150
- Isiisi 151
- Kr250b2 wiring diagram 151
- Other than australian and south african models 151
- Electrical system 15 8 154
- Electrical system 15 10 156
- Sealant 156
- Special tools 156
- The flywheel holder p n 57001 1313 can be used instead of the flywheel holder p n 57001 306 156
- 11 electrical system 157
- Battery 157
- Battery case the electrolyte level should be between the upper and the lower level lines 157
- Battery needs to be charged 157
- Electrolyte level inspection check the level with the electrolyte level gauge on the 157
- Electrolyte specific gravity inspection check battery condition by testing the specific gravity 157
- Fill each cell to the upper level line on the battery case 157
- For example if the battery is rated at 12 ah the charging rate would be 1 a 157
- If the level of electrolyte in any cell is below the lower 157
- If the specific gravity is below 1 0 charge 60 the 157
- Initial charging 157
- Level line add only distilled water to cell until the level is at the upper level line 157
- Of the electrolyte in each cell with a hydrometer 157
- Olf the electrolyte level drops add electrolyte to the 157
- Oread the level of the electrolyte on the floating scale 157
- Read here 157
- Set the charging rate at 1 10 the battery capacity and 157
- Upper level line 2 lower level line 157
- Upper level une before charging 157
- Warning 157
- With fresh electrolyte special gravity 1 80 at a temperature of 30 c 86 f or less let the battery stand for about 30 minutes before charging 157
- A flywheel holder 57001 306 b rotor bolt 158
- A flywheel puller 57001 252 b adapter 57001 1279 158
- A mounting bolts b magneto cover 158
- Charge until the electrolyte gravity becomes 1 80 ata temperature of 30 c 86 f or less 158
- Charging system 158
- Check the electrolyte level after charging 158
- Electrical system 15 12 158
- Flywheel from rotating unscrew the rotor bolt 158
- Lower fairing 158
- Magneto cover removal remove the following 158
- Magneto rotor removal remove the magneto cover using the flywheel holder special tool to keep the 158
- Ordinary charging 158
- Set the charging rate at 1 10 the battery capacity and 158
- Using the flywheel puller special tool and adapter special tool remove the magneto rotor 158
- Warning 158
- 13 electrical system 159
- Battery 159
- Caution 159
- Charging system wiring diagram 159
- Flywheel can cause the magneto to lose their magnet ism 159
- Ignition switch 2 6 pin connector 3 load 4 6 pin connector 5 stator coil 159
- Magneto rotor installation notes using a high flash point solvent wash the tapered 159
- Obe careful not to strike the flywheel itself striking the 159
- Pin connector 7 regulator rectifier 8 20a fuse 9 6 pin connector 159
- Portions of flywheel rotor and crankshaft 159
- Seat side covers fuel tank 159
- See general information chapter 159
- Stator coil removal remove the magneto rotor remove the following 159
- Tighten the magneto rotor bolt to the specified torque 159
- Electrical system 15 14 160
- 15 electrical system 161
- Caution 161
- Electrical system 15 16 162
- Ignition system 162
- Safety instructions 162
- Warning 162
- 17 electrical system 163
- Electrical system 15 18 164
- 19 electrical system 165
- Warning 165
- Electrical system 15 20 166
- 21 electrical system 167
- Electrical system 15 22 168
- Lighting system 168
- 23 electrical system 169
- Headlight bulb replacement notes 169
- License plate light replacement notes 169
- Tail brake light bulb 169
- Wedge base type bulb replacement note 169
- A connector b speedometer cable upper end 170
- A mounting bolts b meter assembly 170
- A triangular mark 170
- Check the coolant temperature gauge circuit wiring 170
- Coolant temperature gauge 170
- Electrical system 15 24 170
- Gauge and or wiring 170
- If all wiring and components other than the coolant 170
- In the housing so that the traiangular mark points down and turn it clockwise 170
- Insert the socket by aligning the tangs with the catches 170
- Lf these readings are not correct the trouble is with the 170
- Lower fairing upper fairing 170
- Meter gauge 170
- Operation inspection 170
- Prepare an auxiliary wire and check the operation of 170
- Removal 170
- Remove the following 170
- See wiring inspection 170
- Temperature gauge unit check out good the gauge is defective 170
- The gauge 170
- 25 electrical system 171
- Oh level warning light inspection 171
- Rear brake light switch adjustment 171
- Switches and sensors 171
- Tachometer inspection 171
- Caution 172
- Coolant temperature sensor inspection 172
- Electrical system 15 26 172
- Installation note 172
- Right and left switch housing 172
- 27 electrical system 173
- Electrical system 15 28 174
- Fuse box 174
- Turn signal relay 174
- Appendix 175
- Table of contents 175
- 2 appendix 176
- Additional considerations 176
- Carburetors 176
- For racing 176
- Spark plug 176
- Appendix 16 3 177
- Spark plug inspection 177
- Appendix 178
- Engine doesn t start starting difficulty 178
- Poor running at low speed 178
- Poor running no power at high speed 178
- Troubleshooting guide 178
- Appendix 16 5 179
- Fuel and oil consumption excessive 179
- Overcooling 179
- Overheating 179
- 6 appendix 180
- Abnormal drive train noise 180
- Abnormal engine noise 180
- Abnormal frame noise 180
- Clutch operation faulty 180
- Exhaust smoke 180
- Gear shift faulty 180
- Appendix 16 7 181
- Battery discharged 181
- Battery overcharged 181
- Brake doesn t hold 181
- Handling and or stability unsatisfactory 181
- 8 appendix 182
- General lubrication nut bolt and fastener tighteness 182
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11 8 BRAKES The master cylinder clamp must be installed with the arrow mark upward Torque the upper clamp bolt first and then the lower clamp bolt to the specification see General Informa tion chapter There will be a gap at the lower part of the clamp after tightening Remove the following A Reservoir Tank Hose End C Mounting Bolts B Brake Hose End NOTE 1 Tighten upper clamp bolts first 2 Lower Clamp Bolt 3 Arrow Mark Use a new flat washer on each side of the brake hose fitting Tighten the banjo bolts to the specified torque see General Information chapter Immediately wipe up any brake fluid that spills Rear Master Cylinder Installation Note the following Use a new flat washer on each side of the brake hose fitting Be sure that the metal pipe is properly fitted into the U shaped notch in the master cylinder Tighten the banjo bolts to the specified torque sec General Information chapter Tighten the rear master cylinder mounting bolts to the specified torque sec General Information chapter Rear Master Cylinder Removal Remove the cotter pin from the rear master cylinder bracket and remove the joint pin Inspection and Adjustment after Installation Check and adjust the following items Brake Pedal Position Rear Brake Light Switch Position see Electrical System chapter Brake Line Air Bleed Brake Drag Braking Power Brake Fluid Leak Disassembly Remove the following parts Dust Cover Retainer Piston with Secondary Cup A Bracket B Cotter Pin C Joint Pin Primary Cup Spring
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